Protective glove with knitted palm covering

ABSTRACT

A protective glove includes a padded back portion and a palm portion. The palm portion can include an engineered material, which is knitted and/or weaved, including at least one of (a) a pattern defining different sized openings, (b) a pattern formed from threads of at least two different materials, and (c) a pattern formed with three-dimensional contours. The protective glove provides enhanced breathability and durability over existing gloves having mesh palm coverings. The protective glove also offers improvements in manufacturing, particularly along the edges of the engineered palm covering. The use of different strands in different portions of the palm covering provides improved strength in select areas of the palm covering while not sacrificing flexibility in other areas of the palm covering.

BACKGROUND OF THE INVENTION

The present invention relates to a protective glove having a knittedpalm covering and a related method of manufacture.

In many contact sports, such as lacrosse and hockey, sticks are elementsof the game. In these sports, a player's wrists, hands and fingers arevulnerable to injury from another player's stick or when hit with a ballor puck. For this reason, players typically wear padded gloves toprotect their wrists, hands and fingers.

To provide improved control of the stick, and to provide breathability,padded gloves are known to include a mesh fabric of a uniform singlemesh pattern, exposed in holes defined by a leather or suede covering.One example of a padded glove having both a mesh fabric insert and anatural or synthetic leather covering is presented in U.S. Pat. No.7,117,540 to Morrow. The mesh fabric is constructed to include a largenumber of closely and uniformly spaced holes to provide a screen likeporosity for ventilation, and the leather covering is located in regionsof the palm intended to contact the wearer's stick.

While conventional mesh fabrics can be utilized in lacrosse, hockey andother gloves to provide certain functional characteristics, they suffera number of shortcomings. For example, mesh fabrics typically are of asingle uniform thickness, which can prevent the mesh from effectivelyconforming to a user's palm, or otherwise can make the glove feel toorigid or too soft. Mesh fabric inserts also are typically die cut from alarger sheet of mesh fabric, which can produce waste. In addition, theresultant edges can be unfinished, having been formed from a simple diecut operation. In turn, these edges are less durable for stitching theinsert to another element of the glove. In addition, mesh inserts aretypically constructed from flat, planar pieces of mesh fabric. Thus, theflat, planar configuration of the mesh does not readily conform to thecontours of a human hand. In turn, the palm of the resulting glove canfeel uncomfortable and/or can bunch unevenly, which can make itdifficult to grasp a lacrosse stick or other implement. Further, mostconventional mesh fabrics have a low coefficient of friction. Thus, whenlarge portions of the palm include such mesh fabrics, the wearer'sability to effectively grip a stick or other implement can decrease,which can impair the player's ability to play well.

Accordingly, there remains room for improvement in the field ofprotective gloves.

SUMMARY OF THE INVENTION

A protective glove including a palm covering including an engineeredmaterial and a method of manufacture are provided. The palm covering isopposite a padded back portion of the protective glove, and can provideimproved control, durability, grip and ventilation as compared toconventional mesh palms.

In one embodiment, the palm covering includes a palm area surface formedpartially or completely from a knitted or woven material, fabric,textile or cloth, any and all of which is considered an engineeredmaterial. Generally, this palm covering can be formed from a unitary,single piece textile that optionally includes no seams, stitches orjoints to join the various portions of the palm covering with oneanother.

In another embodiment, the palm covering includes a knit or weavepattern defining different sized openings. Portions of the palm coveringhaving smaller openings can include a greater thread density thanportions of the engineered palm covering having larger openings. Thedifferent size openings can differ in area by a factor of two or more,for example, alternatively by a factor of ten or more. Portions of thepalm covering having smaller openings can be located in regions intendedto primarily contact the stick, and portions of the palm covering havinglarger openings can be located in regions where improved ventilation isdesired.

In another embodiment, the palm covering and in particular itsengineered material is formed from at least two different materials. Thematerials can be selected from cotton, polyester, nylon, acrylic,aramid, rayon, polyethylene, and polypropylene, for example. A firstportion of the palm covering can include a first material and a secondportion of the palm covering can include a second material differentfrom the first material. The first material can include a higher tensilestrength and/or coefficient of friction in regions intended to primarilycontact the stick, and the second material can include a lesser tensilestrength and/or coefficient of friction in regions not in primarycontact with the stick.

In yet another embodiment, the palm covering, and in particular itsengineered material, can be formed with relief effects, such asthree-dimensional contours. For example, the palm covering can beknitted or woven on a special automated machine and formed with atextured pattern having raised portions and/or recessed portions, orcontours following a user's hand in general. The textured pattern orcontours can correspond to the curvature of the wearer's palm. In otherembodiments, the textured pattern can include an engineered materialthat is thicker in some areas than in other areas.

In still another embodiment, the palm covering, and in particular itsengineered material, can be constructed on an automated machine, such asa knitting and/or weaving machine, so that the resultant palm facingsurface of the covering is contoured to conform to surfaces of a user'spalm, from and/or fingers. For example, the material can be knitted sothat it includes a concave and/or convex configuration so as to conformto a corresponding concave and/or convex surface of a wearer's palm,finger and/or thumb. In this way, when the engineered palm covering canbe placed adjacent the wearer's palm in use; and it readily conforms tothe corresponding contours to provide an exceptional fit.

In even another embodiment, the engineered palm covering and inparticular its engineered material can be constructed on an automatedmachine, such as a knitting and/or weaving machine, so that a perimeterflange is formed to surround all or a portion of an outer perimeter ofthe engineered palm covering. This perimeter flange can be constructedfrom strands of a first material and can surround an interior region ofthe palm covering, which is constructed from strands of a secondmaterial. The first and second strands can be different from oneanother. For example, the strands of the perimeter flange first materialcan be constructed from a durable, tear and rip resistant material, suchas an aromatic polyamide, an ultrahigh molecular weight polyethyleneand/or Nylon 66 thermoplastic resin, such as PA66. The second materialcan be a thermoplastic polymer, for example high density or highstrength polyethylene, polypropylene and/or a polyethylene multifiberyarn. With the durable perimeter flange, the engineered palm coveringcan be durably and reliably stitched, sewn, glued, adhered or otherwiseattached to an adjacent component of the glove without significantconcern of detachment or tearing of the covering from that component.The interior portion can remain supple and comfortable.

In still yet another embodiment, the palm covering and in particular itsengineered material can be constructed to include one or more fusiblestrands, knitted or weaved into the engineered palm covering. Thesefusible strands can include a fusible thermoplastic polymer material,non-limiting examples of which include polyurethane, nylon, polyester,polyolefin and polyamide. These fusible strands can be fused in certainareas corresponding to the palm, fingers and/or thumb that are intendedfor repeated engagement with surfaces of an object, such as a stick,handle and/or grip of an implement. The fusible strands also can befused in certain areas to impart a particular rigid contour to theengineered palm covering in a preselected area. The fusible strandsfurther can be fused along a perimeter flange of a piece of engineeredmaterial so that the perimeter flange can be durably and reliablystitched, sewn, glued or otherwise attached to an adjacent component ofthe glove.

In another embodiment, a method of assembling a protective glove isprovided. The method includes forming an palm covering including anengineered material and coupling the palm covering to a padded backportion, wherein the palm covering extends over the padded back portionto define a pocket for a human hand, wherein the knitted materialincludes at least one of (a) a knit or weave pattern defining differentsized openings, (b) a knit or weave pattern formed from at least twodifferent materials, and (c) a knit or weave pattern formed withthree-dimensional relief effects and/or contours that areself-supporting under the force of gravity. With the latterconstruction, the pattern can maintain a three dimensional form or shapeimmediately after manufacture and can be resistant to completelyflattening out to a two dimensional form upon placement on a horizontalsurface. The method can further include joining a wear resistantcovering over a portion of the palm covering and/or adjacent a portionof the palm covering, the wear resistant covering being natural leather,synthetic leather, natural suede, or synthetic suede, for example. Themethod can still further include forming a wrist guard and/or a cuff andjoining the same to the protective glove.

The protective glove of the current embodiments, with its palm coveringand engineered material, provides enhanced breathability and durabilityover gloves having conventional mesh inserts. The protective glove alsooffers improvements in manufacturing, particularly along the seams ofthe palm covering where it joined with other components of the glove.The use of different strands in different portions of a knitted palmcovering also can provide improved strength and functionality in selectareas of the palm covering while not sacrificing flexibility in otherareas of the palm covering.

These and other objects, advantages, and features of the invention willbe more fully understood and appreciated by reference to the descriptionof the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it isto be understood that the invention is not limited to the details ofoperation or to the details of construction and the arrangement of thecomponents set forth in the following description or illustrated in thedrawings. The invention may be implemented in various other embodimentsand of being practiced or being carried out in alternative ways notexpressly disclosed herein. Also, it is to be understood that thephraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting. The use of“including” and “comprising” and variations thereof is meant toencompass the items listed thereafter and equivalents thereof as well asadditional items and equivalents thereof. Further, enumeration may beused in the description of various embodiments. Unless otherwiseexpressly stated, the use of enumeration should not be construed aslimiting the invention to any specific order or number of components.Nor should the use of enumeration be construed as excluding from thescope of the invention any additional steps or components that might becombined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a dorsal side of a glove including a palmcovering according to a current embodiment;

FIG. 2 is a bottom view of a palm side of the glove of FIG. 1;

FIG. 3 is a side view of a medial side of the glove of FIG. 1;

FIG. 4 is side view of a lateral side of the glove of FIG. 1; and

FIG. 5 is a palm side view of an alternative of the palm covering beforeinstallation relative to a glove.

DESCRIPTION OF THE CURRENT EMBODIMENTS

A protective glove in accordance with a current embodiment isillustrated in FIGS. 1-4 and generally designated 10. While the drawingsare illustrative of a left hand glove, the current embodiments can beincorporated into a right hand glove, which is generally a mirroredversion of the left hand glove. Additionally, the glove 10 asillustrated is designed for use in the game of lacrosse; however, theglove can be used in a variety of other sports or other activities, suchas ice hockey or field hockey.

As shown in FIGS. 1 and 2, the protective glove 10 includes a paddedback portion 12 and a palm side portion 14, between which an interiorspace adapted to receive a wearer's hand, fingers, and thumb is defined.The glove 10 also includes a hand portion 16, a plurality of fingerportions 18 and a thumb portion 20 extending from the hand portion 16, awrist roll 22, and cuff portion 24.

As best shown in FIG. 1, the padded back portion 12 includes multipleprotective elements 26, which can be constructed of one or more layersof foam, polyurethane, polymers or other suitable padding that arecovered with a covering such as a nylon mesh. Each of the protectiveelements 26 can define one or more flex lines therebetween, which allowthe padded back portion 12 to move to provide a better fit and comfortduring play. Flex lines could take on a variety of differentconfigurations and placements as desired.

The hand portion 16 is joined with the cuff portion 24. The cuff portion24 can include one or more cuff panels 28 joined with the hand portion16, generally being joined with the hand portion rearward edge. The cuffpanels 28 can be similar in size, connection and dimension. In someembodiments, the cuff portion 24 can include a floating cuff 30. Thefloating cuff 30 can be disposed immediately under the cuff panels 28.Optionally, the floating cuff 30 can be similar to that described inU.S. Pat. No. 7,636,951 to Morrow et al, which is hereby incorporated byreference in its entirety. The floating cuff can be interposed on awrist of the wearer, located generally between the cuff portion and thewearer's wrist. Optionally, the floating cuff can extend under the cuffopening, as well as the cuff panels and secondary wrist guard cuff.

As shown in FIG. 2, the palm side portion 14 includes a palm covering32, finger coverings 34, and a thumb covering 36. The engineered palmcovering 32 includes a wear resistant material 38 in combination with anengineered material 40. In other embodiments the palm covering 32includes only an engineered material 40, or like the embodiment shown inFIG. 5, the engineered palm covering includes and covers the palm, thefingers and the thumb.

In the embodiment shown in FIGS. 1-4, the engineered material 40 can beformed partially or completely from a knitted or woven material, fabric,textile or cloth, again referred to herein as an engineered material.Various processes for example, knitting and/or weaving processes, can beused to form the engineered material. Generally, the engineered palmcovering can be constructed from a unitary textile material and ismanufactured from strands, which can be in the form of threads, cables,yarn, fibers, filaments, cords and other strand-like elongatedstructures, all referred to herein as strands. Certain conventionalstrands have an indefinite length and can be combined with other strandsto produce a yarn for use in textile materials. The strands used in thisembodiment can be constructed from materials such as thermoplasticpolymers, such as nylon, polypropylene, high density polyethylene,ultra-high molecular weight polyethylene, polyamides, as well asaromatic polyamide and other polymeric materials. Other abrasionresistant and durable material likewise can be implemented. As explainedbelow, the forgoing materials can be mixed and matched within a singleunitary textile material, making up an engineered palm covering toprovide different mechanical and physical properties in differentregions of the engineered palm covering as desired. As mentioned above,the engineered palm covering is a unitary textile material. Unitarytextile materials can be produced via machine implemented mechanicalmanipulation of the strands, thereby producing a weaved or knittedmaterial, or some other type of engineered material. The engineeredmaterial can be constructed automatically, by manipulating strands usingvarious techniques implemented on a machine (rather than performedmanually by a human). The various techniques include knitting, weaving,intertwining and/or twisting, the latter two of which are generallyencompassed by knitting.

The engineered material 40 and optionally the palm covering of thisembodiment can be constructed on a textile manufacturing machine, suchas a knitting machine and/or a weaving machine. A knitting machine canbe utilized to construct one commercial embodiment of the palm coveringand other knitted components if incorporated into the glove. Knittingincludes interlooping strands in a series of connected loops, optionallyforming multiple columns of loops. In weaving, multiple strands arecrossed and interweaved over and under one another at right or othertransverse angles to each other at intersections. Strands used inweaving are usually characterized as warp and weft yarns. Intertwiningand twisting can include techniques such as knotting and braiding, wherestrands intertwine with one another. Generally, knitting can encompassintertwining and twisting herein. Such machines are capable of producingknitted materials with a high degree of precision and reproducibility.With a glove or engineered palm covering constructed from a unitarytextile material or engineered material as described herein, itsconfiguration can be reproduced or replicated with extreme precision.For example, from one palm covering to the next, the dimensions,elasticity, stretchability, contours are virtually identical when thepalm covering is secured to other components of the glove.

Due to this leap forward in glove manufacturing capability, customersalso can obtain gloves having palm coverings with a high degree ofcustomization, in many cases, perfectly fitting the contours of thewearer's hand. For example, a particular player can have a palm with athree dimensional surface or profile. That profile can be determinedand/or digitally captured or three dimensionally mapped into anautomated assembly machine. The automated assembly machine, such as aknitting or weaving machine described in U.S. Published PatentApplication 2017/0340934 to Kohler et al., filed Aug. 21, 2017 and U.S.Published Patent Application 2016/0206939 to Huffa et al., filed Mar.28, 2016, which are both hereby incorporated herein in their entirety,can be programmed with data and/or code relating to or based on thepreferred profile. The machine can then precisely replicate theengineered material in the form of an engineered palm covering.Generally, with the embodiments herein, a high degree of consistency canbe achieved in manufacturing gloves.

Where knitted, the material 40 provides excellent breathability due toits optional screen-like architecture and its repeating pattern ofopenings through the knitted material 40. As used herein, the “openings”in the material refer to the repeating pattern of closely spaced holesbetween adjacent threads, and not other apertures, e.g., aperturespurposely sewn into or punched from the material. The material 40 can beformed from strands of any desired material, optionally cotton,polyester, nylon, acrylic, aramid, rayon, polyethylene, polypropyleneand combinations thereof. The material 40 also can constitute thegussets 42 that join the padded back portion 12 to the palm side portion14. As discussed below, the engineered material 40 can include at leastone of (a) a knit pattern defining different sized openings, (b) a knitpattern formed from threads of at least two different materials, and (c)a knit pattern formed with three-dimensional relief effects. The wearresistant material 38, where used, can include natural or syntheticleather, natural or synthetic suede, or other material which provideabrasion resistance and grip.

As noted above, the engineered material 40 of the palm covering 32 caninclude different sized openings. The different sized openings can bevarious sizes to accommodate better feel and durability where needed.For example, a first portion of the material 40 can include a firstopening size and a second portion of the material 40 can include asecond opening size different from the first opening size. Portions ofthe material 40 having smaller openings can include a greater stranddensity, and portions of the material 40 having larger openings caninclude a lesser strand density. The larger openings can define an areathat is larger than the area defined by the smaller openings, optionallyby a factor of two or more, still further optionally by a factor of tenor more. Though two portions of the material having distinct openingsare discussed above, other embodiments can include a material havingthree or more portions with different sized openings. The openings caninclude a variety of configurations depending upon the knit pattern,with a round knit pattern being shown in FIG. 2. Other openings can beoblong, hex, square, diamond, elliptical, and rectangular, for example.

The material 40 can also include a knit pattern formed from threads ofat least two different materials, effectively a combination fabric. Thethreads can be used in different locations of the knitted material 40 tocreate performance, durability, and manufacturing advantages. Thethreads can include for example cotton, polyester, nylon, acrylic,aramid, rayon, polyamide, polyethylene, or polypropylene. A firstportion of the knitted material 40 can include a first material and asecond portion of the knitted material 40 can include a second materialdifferent from the first material. The first material can include ahigher tensile strength and/or coefficient of friction in regionsintended to primarily contact the stick. The second material can includea lesser tensile strength and/or coefficient of friction in regions notin primary contact with the stick. Though two portions having distinctthreads are discussed above, other embodiments can include a knittedmaterial having three or more portions with different threads.

Optionally, the material 40 can be formed with relief effects and/orconcave or convex contours, effectively being formed withthree-dimensional contours to accommodate better fit, feel anddurability. For example, the material 40 can be formed with a texturedpattern having raised portions or ridges and/or recessed portions. Thetextured pattern can correspond to the curvature of the wearer's palm,in some embodiments. In other embodiments, the textured pattern caninclude material 40 that is thicker in some areas than in other areas.

A method for assembling the protective glove 10 generally includesforming a palm covering including a material and coupling the palmcovering to a padded back portion to define a pocket for a human hand.The engineered material includes at least one of (a) a knit patterndefining different sized openings, (b) a knit pattern formed fromthreads of at least two different materials, and (c) a knit patternformed with three-dimensional relief effects. The step of coupling thepalm covering to a padded back portion can include forming a border inthe material and joining the material to the padded back portion along aseam. The palm covering can include primarily a wear resistant materialin some embodiments, for example as shown in FIG. 2, in which thematerial spans one or more apertures or gaps in the wear resistantmaterial. In other embodiments, the palm covering can includesubstantially only an engineered material. As noted above, the materialcan additionally include a finished border to simplify and strengthenthe joining of the palm covering to the padded back portion and/or tothe wear resistant material. The method of assembling the protectiveglove can additionally include forming a wrist roll and a protectivecuff in the protective glove.

An alternative embodiment of the glove, in particular a palm covering132, is illustrated in FIG. 5. The palm covering of this embodiment issimilar in structure, function and operation to the engineered materialand/or palm covering of the above embodiments, with several exceptions.For example, in this construction, the palm covering 132 includes both apalm portion 132 as well as finger portions 134 and a thumb portion 136all of these portions are formed from a unitary contiguous piece ofengineered material 140. This engineered material can include variousfeatures as described below. Further, it will be appreciated that thesefeatures may be incorporated into a smaller, independent and separatepalm covering components, finger portion and/or thumb portion, dependingon the application. Further, the components of the palm covering 132 canbe covered by other materials in the preselected locations, such aswearable, more durable materials.

The engineered material 140 optionally can be a unitary knitted or woventextile material. This material can include various knit patterns indifferent locations of the palm covering 132. These knit patterns can beselected to provide certain properties characteristics to areas of thepalm covering. For example, the finger portions can include regions134R. These regions can be constructed from a first knit pattern that isdifferent from a second knit pattern 135 that is immediately adjacentthe regions 134R. These regions 134R, for example, can include multipleridges or recesses 134S in the first knit pattern that are formed as aresult of a knitting operation in that region, performed by theautomated assembly machine. These ridges or recesses 134S can enhancethe coefficient of friction of the palm covering 132 in these regions.The second knit pattern 135 can include a smoother, more compliant andflexible surface due to the second knit pattern. This can provide moreflexibility at the joints of the fingers that a user can more easilygrasped an object. The thumb portion 136 can include a knit pattern inregion 136 similar to that of the first knit pattern.

As another example, the palm region 132R which generally overlies aportion of the palm can include a third knit pattern that provides aplurality of large, visible 0.5 mm to 5.0 mm openings 1320. Theseopenings can provide enhanced ventilation to the palm. Of course suchopenings can be distributed elsewhere, for example in the fingerportions and/or thumb portion depending on the application. Optionally,the openings can be bounded by a border. The border can compriseinterlooped strands that are uncut, that is, the openings are not cut bya device or process in order to form the border and the associatedinterlooped strands in the border remain intact and uncut.

The engineered material 140, and in particular the palm covering 132 canbe constructed with the different knit patterns as mentioned above. Insome cases, these knit patterns can cooperatively form one or morecontours 132C, 134C and/or 136C. These contours can mimic the naturalcontours of corresponding features of a wearer's hand. For example thecontours 134C of the finger portions 134 can be convex on the outside ofthe palm 132, that is, they bulge out of the page of FIG. 5. Conversely,on the back side of the palm covering 132, those contours 134C wouldappear as concave contours. The same is true for the thumb contour 136C.The material covering the palm also can include a contour 132C whichlikewise can be convex, bulging out of the page of FIG. 5. Thesecontours can be formed as a direct result of the knitting and/or weavingor other automated process used to make the engineered material 140.These various contours also can be self-supporting under the force ofgravity, for example when the palm covering 132 is placed on a flatplane, the contours 134C with project upwardly in a three-dimensionalfashion from the support plane. The same is true for the contours 136Cand 132C. Of course, other contours could be incorporated into theengineered material 140, such that recesses or reliefs are formed in theengineered material 140.

The engineered material 140 optionally can include strands of differentmaterials. These materials can be distributed in regions or areas of thepalm covering 132 depending on the function of the same. For example,the perimeter flange 150 that generally extends along the lateral sideof the hand, over the outline of the fingers and thumb, and back alongthe medial side of the palm, as well as other regions of the palmcovering 132, depending on the application, can be constructed fromstrands of a first material, which can be less elastic, and/or moreabrasion resistant and more durable than strands of a second materialthat is disposed inwardly from that perimeter flange 150. With such aconstruction, this perimeter flange can be well-suited for sewingstitching, gluing, adhering, welding or otherwise joining with aperipheral allowance or gusset or other padding associated with othercomponents of the glove, such as the dorsal backhand or other gussets.In some cases, the perimeter flange can be of a width W1 that isoptionally at least 2.0 mm, further optionally at least 2.5 mm, evenfurther optionally at least 5.0 mm. With this width, there can beadequate surface area along the outer perimeter of the palm covering 132to stitch the perimeter flange to another glove component. Due to thedurability of this perimeter flange 150, the engineered material 140 inthe regions where it is joined to other components can withstandextensive pulling forces that might otherwise tear or damage thematerial 140 along points of attachment.

Optionally, the first material can be at least one of an aromaticpolyamide, an ultra-high molecular weight polyethylene, and a polyamide.One suitable aromatic polyamide is poly-para-phenylene terephthalamide,sold under the commercial name of KEVLAR® by DuPont of Wilmington, Del.The first material optionally can have strands having: a tensile modulusof elasticity of optionally 400-1000 g/d, further optionally 500-900g/d, and even further optionally at least 500 g/d; an elongation atbreak of optionally 1.0% to 10.0%, further optionally of 3.0% to 2.4%,further optionally 3.6%; a breaking tenacity of optionally 100-300cN/tex, further optionally 150-250 cN/tex, even further optionally203-208 cN/tex; and a tensile strength of optionally about 2,000-10,000MPa, further optionally 3,000-6,000 MPa and even further optionallyabout 3,600 MPa. This first material can be less elastic and moreabrasion resistant and durable and tear resistant than the secondmaterial used in for example, inward from the perimeter flange 150.

As mentioned above, the first material can be a polyamide, such aspolyamide 6,6, which is commonly known as Nylon 66 thermoplastic resinor PA66, having a CAS Number of 032131-17-2. The polyamide can have amelting point in the range of 220° C.-250° C. and a specific gravityrelative to water of 1.15 g/cc measured using ASTM D792. The polyamidecan have the molecular formula (C12 H22 N2 O2)n, and a densityoptionally of 1.30 g/cm³-1.60 g/cm³, further optionally 0.90 g/cm³-1.2g/cm³ at 20° C. as measured using EN ISO 1183-1. The polyamide can havea hardness of 80 Shore D measured using ASTM D2240, a tensile strengthof about 82.7 MPa, measured using ASTM D638, and having a tensilemodulus of optionally 2.0 GPa to 4.0 GPa, further optionally 2.5 GPa to3.0 GPa using ASTM D638. The polyamide, when in the form of amultifilament yarn, can exhibit 30%-50% elongation at break, furtheroptionally 39%-42% elongation at break, yet further optionally about 40%elongation at break measured using ASTM D638. The polyamide can exhibitthermal decomposition temperatures greater than 310° C. Thus, when thepolyamide is used with the current embodiment, the molding temperaturesto mold a head over a portion of the pocket can be optionally less than350° C., further optionally less than 325° C., yet further optionallyless than 310° C., even further optionally less than 280° C. Suitablepolyamides can be optionally ULTRAMID® A3X2G5 Uncolored Polyamidecommercially available from BASF of Florham Park, N.J., furtheroptionally Emarex™ Polyamide Resin commercially available from MRCPolymers Inc. of Chicago, Ill., yet further optionally Polofil Nylon 66commercially available from The Plastic Group of America of Woonsocket,R.I. Of course a variety of other polyamides can be suitable for thefirst material to construct the first strands and associated yarns inthe various edges as well as other regions of the glove depending on theapplication.

Further optionally, inside the perimeter flange 150, the engineeredmaterial 140 can include strands constructed from a second material. Thesecond material can be a thermoplastic polymer, for example high densityor high strength polyethylene, polypropylene and/or a polyethylenemulti-fiber yarn. The second material optionally can have strandshaving: a modulus of elasticity of optionally 0.1-2.0 GPa, furtheroptionally 0.5-1.0 GPa; elongation at break of optionally greater than50%, further optionally greater than 100%, even further optionallygreater than 500%; and a tenacity of optionally 20-350 kN/tex, furtheroptionally 30-320 kN/tex, and even further optionally 50-100 kN/tex, andeven further optionally less than 150 kN/tex. The second material caninclude strands optionally in a range of 100 Denier to 1000 Denier,further optionally 150 Denier to 840 Denier, even further optionally 210Denier to 750 Denier, yet further optionally 300 Denier and/or 420Denier. In some cases, the second material can generally be more softand flexible than the first material, optionally due to the differencesin their construction, or due to different knitting or weaving processesused to make these components.

If desired, the first and second materials can include a UV inhibitor toprotect the strands when the engineered material of the palm covering isused in direct sunlight. Of course, the palm covering can be constructedfrom the first material and second material, only one of the twomaterials, and/or other additional materials depending on theapplication.

It will also be appreciated that the perimeter flange 150 can form theoutermost free edge of the engineered palm covering 132 of thisembodiment. Via the automated processes disclosed herein, the entirepalm covering 132 can be constructed from the engineer material 140without producing any waste or other material from which the palmcovering 132 must be removed. In turn, this can reduce waste and improvemanufacturing of the subject palm covering 132.

Optionally, the engineered palm covering 132 can be knitted or weavedfrom a engineered material, such as a textile material having certaintypes of strands for example fusible strands disposed in certain regionsfor certain functionality. For example as shown in FIG. 5, region 132Fcan include a plurality of fusible strands. These fusible strands can befused together to make that region generally more rigid and/or stiff.This can be suitable for applications where the region 132F comes incontact with a stick or other implement, or is otherwise a region ofhigh wear. With the fusible strands in this region, the wear can bereduced to prolong the useful life of the palm covering 132.

One or more of the strands used to knit or weave the engineered materialmay be a fusible strand that includes a fusible thermoplastic polymermaterial, non-limiting examples of which include polyurethane, nylon,polyester, polyolefin, and polyamide. The fusible strands may be formedfrom a single, fusible material or multiple layers of materials in whichan outer layer is a fusible material. For example, the fusible strandscan include a fusible material layer surrounding an interior strandmaterial, which may or may not be fusible, in a core-sheath typeconfiguration. In another example, a strand or strip of fusible materialmay be applied to a strand made from a non-fusible material. Following afusing treatment, the fusible strand material melts and/or softens toform a “molten” material that at least partially surrounds thenon-fusible material, forming a coated or partially coated strand.

Optionally, the fusible strand may be formed entirely of a thermoplasticpolymer material or include a thermoplastic polymer coating. Thethermoplastic polymer coating may be applied using any known technique,non-limiting examples of which include co-extrusion, dip coating, andspray coating. The thermoplastic polymer coating can be a reactivecoating material that exhibits thermoplastic properties prior to curingand thermosetting properties after it has been exposed to curingconditions. Such a reactive coating exhibits thermoplastic propertiesbelow a certain temperature, allowing the material melt/soften and fusewith adjacent strands. Following a curing treatment, the reactivecoating cures to a material with thermoset properties, such as byforming cross links, for example. The curing treatment can includeheating the material to a second temperature, higher than the firsttemperature at which the thermoplastic material melts and fuses.Optionally, the curing treatment includes increased temperature andpressure and/or the addition of a cross-linking agent. One non-limitingexample of a reactive coating includes an acrylic acid copolymer and across-linking agent. Optionally, the reactive coating is a materialavailable from BASF Corporation under the tradename ACRODUR®. In thismanner, the fused area of the palm covering 132 may be thermoset, whichcan increase the hardness and/or stiffness of the fused area.

Optionally, the fusible strand may be constructed from a firstthermoplastic polymer with a first melting temperature and a secondthermoplastics polymer with a second melting temperature that is lessthan the first melting temperature. The first and second thermoplasticpolymers may be configured in a core-sheath type configuration or thesecond thermoplastic polymer may be provided as a strand or stripapplied to the first. A heat-based fusing treatment can be applied toheat the fusible strand to a temperature sufficient to melt the secondthermoplastic polymer, but below the melting temperature of the firstthermoplastic polymer. Further optionally, a fusible strand may becombined or twisted with a non-fusible strand or yarn to form a fusibleyarn including such fusible strand.

Non-fusible material may include natural or synthetic materials that areincapable of fusing or may include a fusible material that is configuredto not fuse during the prescribed fusing treatment. For example, thenon-fusible material may have a higher melting point than the fusiblematerial and thus not melt/soften during the prescribed fusingtreatment.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,”“upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are usedto assist in describing the invention based on the orientation of theembodiments shown in the illustrations. The use of directional termsshould not be interpreted to limit the invention to any specificorientation(s).

The above description is that of current embodiments of the invention.Various alterations and changes can be made without departing from thespirit and broader aspects of the invention as defined in the appendedclaims, which are to be interpreted in accordance with the principles ofpatent law including the doctrine of equivalents. This disclosure ispresented for illustrative purposes and should not be interpreted as anexhaustive description of all embodiments of the invention or to limitthe scope of the claims to the specific elements illustrated ordescribed in connection with these embodiments. For example, and withoutlimitation, any individual element(s) of the described invention may bereplaced by alternative elements that provide substantially similarfunctionality or otherwise provide adequate operation. This includes,for example, presently known alternative elements, such as those thatmight be currently known to one skilled in the art, and alternativeelements that may be developed in the future, such as those that oneskilled in the art might, upon development, recognize as an alternative.Further, the disclosed embodiments include a plurality of features thatare described in concert and that might cooperatively provide acollection of benefits. The present invention is not limited to onlythose embodiments that include all of these features or that provide allof the stated benefits, except to the extent otherwise expressly setforth in the issued claims. Any reference to claim elements in thesingular, for example, using the articles “a,” “an,” “the” or “said,” isnot to be construed as limiting the element to the singular. Anyreference to claim elements as “at least one of X, Y and Z” is meant toinclude any one of X, Y or Z individually, and any combination of anynumber of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

1. A protective glove, comprising: a padded back portion including aplurality of pads; a palm portion including a finger portion, a thumbportion, and a palm portion, the palm portion connected to the paddedback portion to form a finger sheath, a thumb sheath, and an openingcapable of receiving a human hand; and a gusset joining the palm portionwith the padded back portion; wherein the palm portion includes anengineered material including at least one of (a) a knitted patterndefining different sized openings, (b) a knitted pattern formed fromstrands of at least two different materials, and (c) a knitted patternforming a three-dimensional contour that withstands the force of gravitywhen placed on a horizontal surface.
 2. The protective glove of claim 1,wherein the palm portion includes a first region having a first threaddensity and includes a second region having a second thread density, thesecond thread density being less than the first thread density.
 3. Theprotective glove of claim 1, wherein the at least two differentmaterials are selected from a group consisting of: cotton, polyester,acrylic, aramid, rayon, polyethylene, polyamide and polypropylene. 4.The protective glove of claim 1, wherein the three-dimensional contourincludes a textured pattern having raised portions and/or recessedportions.
 5. The protective glove of claim 1, wherein the palm portionincludes a perimeter flange, wherein the perimeter flange is constructedfrom at least one of an aromatic polyamide, a polyamide and anultra-high molecular weight polyethylene, wherein the perimeter flangeis joined with a wear resistant covering that extends over a portion ofthe engineered material along an edge of the engineered material.
 6. Theprotective glove of claim 5, wherein the wear resistant material isselected from the group consisting of natural leather, syntheticleather, natural suede, and synthetic suede.
 7. The protective glove ofclaim 1, wherein the finger portion and the thumb portion of the palmportion include the engineered material, which is a knitted material. 8.The protective glove of claim 1, wherein the engineered material is aknitted textile including a plurality of interlooped strands; whereinthe palm portion includes a region comprising a plurality of fusiblestrands that are fused to one another, wherein the region including thefused plurality of fusible strands provides support to thethree-dimensional contour.
 9. The protective glove of claim 1, whereinthe palm portion includes the knitted pattern defining the differentsized openings, wherein each of the different sized openings include aborder that comprises a plurality of interlooped strands that are uncut,wherein the palm portion includes a perimeter flange, wherein theperimeter flange is constructed from at least one of an aromaticpolyamide, a polyamide and an ultra-high molecular weight polyethylene,wherein the perimeter flange is joined with a wear resistant coveringthat extends over a portion of the engineered material along an edge ofthe engineered material.
 10. A protective glove, comprising: a paddedback portion; a palm covering including a finger portion, a thumbportion, and a central palm portion, the palm covering joined with thepadded back portion to form a finger sheath, a thumb sheath, and anopening capable of receiving a human hand; wherein the palm coveringincludes an engineered material constructed from a single, unitaryknitted textile, the engineered material forming a three dimensionalcontour corresponding to at least one of a palm, film and finger of awearer of the glove, the three-dimensional contour capable ofself-supporting itself against the force of gravity when placed on ahorizontal surface, wherein the palm covering includes a perimeterflange surrounding an interior portion of the palm covering, theperimeter flange constructed from a plurality of strands of a firstmaterial that are different from a plurality of strands of a secondmaterial from which the interior portion of the palm covering isconstructed.
 11. A method of making a protective glove comprising:mechanically manipulating a plurality of first and second strands withan automated pocket assembly machine during an automated process to forma palm covering during the automated process, the palm coveringincluding predefined three dimensional concave contours as a directresult of the automated process, the palm covering including a palmportion integrally formed with at least one of a finger portion and athumb portion; heating the plurality of first strands so that theplurality of first strands at least partially melt to form a firstmolten material that fuses individual ones of the first plurality ofstrands with one another; cooling the plurality of first strands so thatthe first molten material solidifies, thereby forming a fused region ofthe palm covering; and coupling the palm covering to a padded backportion, wherein the palm covering and padded back portion cooperativelydefine a pocket for a human hand.
 12. The method of claim 11, whereinthe palm covering includes a knit pattern includes a first region havinga first thread density and includes a second region having a secondthread density, the second thread density being less than the firstthread density.
 13. The method of claim 11 comprising: forming aperimeter flange around at least a portion of a perimeter of the palmcovering, wherein the perimeter flange is constructed from a pluralityof strands of a material that is at least one of an aromatic polyamide,a polyamide and an ultrahigh molecular weight polyethylene.
 14. Themethod of claim 11, comprising: forming a perimeter flange around atleast a portion of a perimeter of the palm covering, wherein the fusedregion is located at these partially within the perimeter flange. 15.The method of claim 11, comprising: knitting the palm covering with theassembly machine during a knitting process.
 16. The method of claim 11,wherein the plurality of second strands are constructed from anon-melting material, wherein the plurality of second strands do notmelt during the heating step.
 17. The method of claim 11 comprising:joining a wear resistant covering with a portion of the palm covering.18. The method of claim 17, wherein the wear resistant material isselected from the group consisting of natural leather, syntheticleather, natural suede, and synthetic suede.
 19. A method ofmanufacturing a protective glove comprising: mechanically manipulating aplurality of strands with an automated pocket assembly machine during anautomated process to form a unitary textile material that is anengineered palm covering including a first region and a second regionjoined with one another as integral parts of the same unitary textilematerial, the first region having a first set of physical properties,the second region having a second set of physical properties differentfrom the first set of physical properties, wherein the engineered palmcovering forms a predefined, three dimensional concave contour producedduring the mechanically manipulating step, the concave contourconfigured to correspond to a contour of a hand of a wearer of theglove, the concave contour constructed via the automated process so thatthe concave contour retains a three dimensional shape that withstands aforce of gravity when placed on a horizontal surface.
 20. The method ofclaim 19 comprising: joining a backhand portion to the palm covering,and joining a cuff to the backhand portion, wherein the automatedprocess is a knitting process.